Optical fiber cables

ABSTRACT

The specification describes an optical fiber drop cable with a flat configuration and having two side-by-side subunits. One of the subunits contains a cable strength member, e.g. a steel wire or stranded wire. The other subunit is an optical fiber subunit, which contains the optical fiber(s), and also contains one or more additional strength members. In a preferred embodiment, the cable is dry, and has conformal encasements that couple the optical fiber(s) to the outer cable sheath.

FIELD OF THE INVENTION

This invention relates to optical fiber cables specially adapted fordrop line applications.

BACKGROUND OF THE INVENTION

Fiber-to-the-premises (FTTP) from local telephone and cable serviceproviders is rapidly being implemented. This service requires abroadband optical fiber distribution network comprising local opticalfiber distribution cables that are installed in neighborhood and citystreets. The local distribution cable is a large fiber count(multi-fiber) cable. Single fiber or few fiber cables are used for the“drop” line from the street to the premises. In many cases, aerial droplines are used, and these have special requirements. In other cases,buried drop lines are used, and these have different specificrequirements.

Optical fiber drop cables are made in several designs. Most of thesedesigns mimic earlier copper cable versions. Physical resemblance isdeliberate, so that the external cable appearance matches that ofexisting copper versions, and standard hardware and installationequipment may be used for both. Thus “A-drop” optical fiber cable is anoptical fiber version of A-drop copper cable, and is made in the sameflat or ribbon-like configuration. Aerial drop cable typically has oneor more strength members for support. A common A-drop or flat cabledesign comprises one or more optical fibers between two strengthmembers. See for example, U.S. Pat. No. 6,501,888.

Optical fiber cables also commonly contain gel-filling compounds forpreventing water excursion in the cable. When water enters a cable, flowof water along the length of the cable is blocked by the gel. However,gel filled cables are time consuming to install and repair, as the gelmust be completely removed from the optical fiber prior to splicingoperations. Moreover, since the drop wire is typically attached to theside of a customer's home or building, bleeding of ingredients in thecable onto the customer's building may cause cosmetic or other problems.

Since aerial drop cables are subjected to considerable movement and sagdue to wind and ice build-up, and due to mechanical strain caused bydifferential thermal expansion, aerial drop cables commonly have a loosefiber design. In this design the optical fibers are loosely received,“floating” within the cable encasement. The premise is that the opticalfibers are mechanically isolated from at least some of this movement.However, a drawback to this design is that the cable may suffer fiberretraction due to the movement just mentioned. Fiber retraction occurswhen the outer sleeve of the optical fiber cable sags or is stretchedrelative to the optical fibers. Excessive fiber retraction may result indamage or breakage of the fibers.

Several examples of drop cable are described in U.S. Pat. No. 4,761,053.Most of these examples describe copper drop wire but a few optical fiberversions are given as well. These show loose fiber designs as justmentioned.

Another FTTP drop cable design is shown at pages 500-506 of theProceedings of the 51^(st) International Wire and Cable Symposium. Thisdesign is a combined flat optical fiber cable and a wire support member.

New designs offering for FTTP drop cable that offer compact size and lowcost are continually being sought.

STATEMENT OF THE INVENTION

We have designed an optical fiber cable suitable for drop cableapplications that has a compact flat profile. The new design has abinary construction of two subunits molded together side-by-side.Preferably, the two subunits match geometrically. One subunit containsthe optical fibers, and the other unit contains a strength member. Thesubunit containing the optical fibers also contains one or more separateand additional strength members. In a preferred embodiment, the cablehas a coupled fiber design, and is dry. The coupled design forms aunitary assembly that is robust, and resistant to fiber retraction. Thecombination of a flat cable profile, with a strength member that iseasily separated from the optical fiber subunit, and with a separatestrength member is the optical fiber subunit, results in a design thatis well adapted to multiple drop cable applications.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a sectional view of one embodiment of the optical fiber dropcable of the invention;

FIG. 2 is sectional view of the subunit that contains the optical fiberassembly;

FIG. 3 is a sectional view of the subunit that contains the strengthmember;

FIG. 4 is a schematic view showing the separation of the two subunits inthe cable;

FIGS. 5 and 6 are figures similar to that of FIG. 1 showing alternativecable designs according to the invention; and

FIG. 7 is a schematic view of a drop cable installation.

DETAILED DESCRIPTION

Referring to FIG. 1, a flat optical fiber drop cable is shown generallyat 10, with optical fiber subunit 12 and strength member subunit 13.Both are encased in encasement 11. The subunits are preferablyapproximately the same size, as shown, which imparts symmetry to thecable cross section. Alternatively, they may be different sizes.Symmetry, if desired, may be realized in the latter case by using asymmetrical die for extruding the encasement 11. In the embodimentshown, the optical fiber subunit contains two fibers 15. One fiber, ormore than two fibers, may also be used.

The subunits 12 and 13 are shown in more detail in FIGS. 2 and 3. FIG. 2is a cross section of the optical fiber subunit 12. Here, there is oneoptical fiber shown at 15. The optical fiber is a conventional coatedglass or plastic fiber. The optical fiber subunit may have a loose fiberdesign, where the optical fiber floats in a tube. However, the preferreddesign is that illustrated, where the optical fiber is embedded in aninner polymer layer 14, coupled to conformal encasement layer 18, tocomplete the optical fiber subunit. The optical fiber subunit is cabledtogether with subunit 13 in outer cable sheath 11.

As shown, in the portion of the cable 10 that contains the optical fibersubunit, there are three polymer layers 11, 14, and 18. To distinguishand define these, the following description will refer to the innerencasement that surrounds the optical fiber, and couples the opticalfiber to the outer parts of the cable, as the optical fiber encasementor OF encasement. Layer 18, the conformal layer that surrounds the OFencasement, and contains one or more strength members, is referred to asthe OFSM encasement, and the outer encasement 11, which forms the outercable jacket, is referred to as the cable encasement. In the preferredembodiment of the invention, all three layers are present. The opticalfiber subunit assembly that comprises the OF encasement and the OFSMencasement is referred to below as the OF subunit. In the embodimentshown in FIGS. 1, 5, and 6, the OF encasement contains 2 optical fibers15, and the OFSM encasement contains two strength members 16 and 17.

In the designs illustrated, the two strength members 16 and 17 arelocated on either side of the optical fiber(s) 15. The strength members16 and 17, and the optical fiber(s) 15, are preferably “in-line”, i.e.their centers lie on the same axis. The strength members 16 and 17 haveseveral useful features. They are made of a material with high tensilestrength, e.g. a resin with reinforcing fibers. Fibers for this purposeare well known and widely used. Examples are glass fibers and Kevlar(aramid) fiber. The resin may be any of a wide variety of polymer hostmaterials, and is preferably a thermoset urethane or acrylate resin,cured by heat or UV radiation. Although metallic wires could also beused, nonmetallic reinforced fiber strength members are preferred, asthey do not need to be grounded and are not vulnerable to lightningstrikes and induced electric currents.

The strength members 16 and 17 also serve as armoring to protect thesides of the optical fiber subunit. The most vulnerable part of a cablewith the shape shown is the outer edge of the optical fiber subunit 12.Sharp instruments used for splicing, or sharp surfaces encountered ininstallation tend to impact the edges of the subunit. With the in-linedesign, the optical fiber system is effectively protected from thesehazards. As described in greater detail below, when the optical fibersubunit is stripped from the strength member subunit, the optical fibersare still protected.

The strength member subunit is shown generally at 13, and is referred tobelow as the SM subunit. One embodiment of the SM subunit is shown incross section shown in FIG. 3. FIG. 3 shows a SM subunit with strengthmember 19, and strength member encasement 20. The latter will bereferred to as the SM encasement. The material of the strength member inthe SM subunit may be the same as, or different than, the material ofthe OFSMs 16, 17. For low cost and high strength, steel is particularlysuitable. Steel also provides a conductor for a potential groundconnection, and is useful for locating buried cable. The SM subunit maycomprise either a single steel strand, or a braided steel ropeconsisting of small steel strands in applications where greaterflexibility is desired.

For applications where risk of damage to the overall cable structure dueto lightning is high, a non-conductive strength member is preferred. Thepurpose of the SM subunit is to provide tensile strength to the cableduring installation and service; the SM subunit does not need to providecompressive strength. Therefore, a non-metallic SM unit can be flexible,consisting of flexible fiberglass, aramid yarn, or a semiflexiblefiberglass/resin reinforcement. A preferred embodiment uses a 2.7 mmsemiflexible fiberglass/resin reinforcement, upjacketed to the samediameter as the optical fiber subunit. A nonmetallic cable constructionusing a flexible strength member 19 overcomes a serious limitation ofprior art designs such as those taught in U.S. Pat. No. 6,501,888. Thesedesigns rely on rigid fiberglass reinforcements to provide tensile andcompressive strength, and as a result these cables are very rigid anddifficult to work with during installation. The modular cable 10 issignificantly more flexible than prior art designs when a flexiblenonmetallic strength member 19 is utilized.

Materials for the encasement layers may be selected from a wide varietyof polymers. Suitable choices are polyolefins and ester-based polymerssuch as polyethylene, polypropylene, polyvinylchloride, ethylene-vinylacetate polymers, ethylene acrylic acid polymers, ester-based polymers,and co-polymers of the foregoing. A specific example is Geon W2402, adrop cable grade polyvinylchloride resin available from the PolyoneCorporation. These materials are given by way of example are notlimiting of potential suitable materials. In each case the density andother properties of the polymers may be tailored by methods well knownin the art to provide the characteristics desired. For example, theoptical fiber drop cables may require fire-retardant polymers. Anexample is DGDA-1638-NT, a fire-retardant low-smoke zero-halogen resinavailable from the Dow Chemical Company. The encasements may be appliedby any suitable technique, e.g. extrusion, or UV coating.

Differential shrinkage between the material comprising the secondaryencasement and the primary encasement will also affect the amount oflongitudinal shrink-back of the drop cable in service. To reduce thateffect, the material of the cable encasement may contain 10% or more ofa filler, such as calcium carbonate. The other encasement layers mayalso contain at least 10% of a filler.

The detrimental consequences of shrink-back as well as fiber retractionare addressed inherently by the preferred cable design of the invention.In conventional drop cables that have a loose fiber design, the outersheath of the cable is free to shrink or distend (due to cable sag)independent of the optical fiber assembly. In the cable designsdescribed here, the coupling of the optical fiber system to the outersheath (cable encasement ) minimizes differential dimensional changesbetween the optical fiber system and the cable encasement, reducing thelikelihood of separation between elements in the cable, or breaking ofthe optical fibers. In addition, the coupled cable structure of theinvention will retard both shrinkage and sagging of the overall cableassembly.

Increased coupling of the optical fiber assembly to the OF encasement,and the OF encasement to the cable encasement, to yield the advantagesmentioned above, is achieved in part by adhesion between the opticalfibers and the OF encasement, the OF encasement and the OFSM encasement,and the OFSM encasement and the cable encasement. This adhesion mayoccur through fusing the units together using heat in cable processing,or through frictional coupling of the various components.

While the cable designs described here are primarily intended for aerialor direct-buried drop applications, the cable encasement material may bespecially designed for air blown installations. See U.S. patentapplication Ser. No. 10/233,719, filed Sep. 3, 2002, incorporated byreference herein. For aerial drop cable applications, the cableencasement may be loaded with carbon black to prevent degradation causedby UV sunlight. Other details of appropriate cable encasement materialsmay be found in U.S. Pat. No. 6,317,542.

Another feature of the drop cable design of the invention is that thearrangement of the dual strength members (16, 17 in FIG. 1) allowsconvenient stripping of the optical fiber subunit for splicing etc. Toseparate the optical fibers from the rest of the OF subunit, the end ofthe OF encasement may be notched at a point on either side of theoptical fibers, and, using the two strength members, the subunit may bepulled apart to expose the optical fibers. The individual fibers arestripped, and spliced or connected, following conventional practice.

Likewise, a similar procedure may be used for separating the OF subunitfrom the SM subunit. Here, the SM strength member is pulled away fromthe cable. This separation is illustrated in FIG. 4 where the unitarycable is shown at 41. The cable is easily separated into the subunitsdescribed above, i.e. OF subunit 43, and SM subunit 44. In FIG. 4 the OFsubunit is shown leading to a connector box 47 on the customer premises,and to an optical fiber connector 46, and the SM subunit leads to aclamping device 45 also associated with the customer location. Inseparating the OF subunit from the cable, the encasements can be chosensuch that the strength member (19 in FIG. 3) alone separates from theremainder of the cable. That is easily accomplished by suitable choiceof the encasement 20 in FIG. 3. A low strength polymer, and one thatadheres to the cable encasement, can ensure that the strength member 19rips through the SM encasement. This is also easily implemented if theSM encasement is omitted.

The OF encasement, and the SM encasement, may comprise more than onelayer, each having the properties indicated. In some cases, it may beadvantageous to have an inner adhesive encasement layer adjoining theoptical fiber assembly. Or, as may be preferred in some cases, anencasement may be omitted. Two such embodiments are shown in FIGS. 5 and6

FIG. 5 shows an embodiment where the SM encasement is omitted. FIG. 6shows an embodiment where both the SM encasement and the OF encasementare omitted. One function of the SM encasement is to simplify thecabling process. If both the OF subunit and the SM subunit areapproximately the same diameter, the extrusion of a symmetrically shapedcable is straightforward. However, with proper choice of the cablingequipment, the symmetrical shape can be achieved using subunits ofunequal diameter. Another option in this connection is to use a strengthmember 19 of approximately the same diameter as the OF subunit.

In a preferred embodiment for aerial installation, the SM subunitcomprises a single steel strand, approximately 2.0 mm in diameter,up-jacketed to match the outer diameter of the OF subunit. Therelatively large steel strand is necessary to provide sufficient tensilestrength such that the cable can survive ice and wind loading.

In a preferred embodiment for direct-buried installation, the SM subunitcomprises a single steel strand, approximately 1.2 mm in diameter,up-jacketed to match the outer diameter of the OF subunit. This smallersteel strand has sufficient tensile stiffness for the application, aswell as sufficient conductivity to be located using conventionalequipment.

FIG. 7 is a schematic of an aerial drop wire installation, andillustrates a main feature of the invention. The drop cable 71 is showninstalled on the side of building 72. The cable is separated at point S,and the SM strength member is attached to clamp 73 on the premises. TheOF subunit of the cable leads to a connection box 77, where the OFsubunit is stripped, as described earlier, and the optical fibersconnected to the customers system. An advantage of the cable design ofthe invention is that the OF subunit loop 75, where the OF subunit is nolonger supported or protected by the SM subunit, continues to haveessentially equivalent protection and support due to the strengthmembers in the OF subunit. This allows the loop 75 to extend oversignificant distances where the installation requires that. In addition,if the OF subunit is constructed from flame-retardant materials, it maybe directly routed into a customer premises as a breakout cable ifdesired. During termination of the fiber, the strength members in the OFsubunit may also be used to conveniently provide strain relief for thefibers. The fiber and strength member encasements may be stripped away,leaving only strength members and bare fiber. The strength members maybe trimmed and clamped or glued to the connection box, leaving slackfiber entering a connector. This slack fiber can prevent breakage offiber splices and associated service outages caused by stress resultingfrom thermal or mechanical strain of the cable.

Modifications in the geometry of the elements shown may be made whilestill achieving the benefits of the invention. For example, the strengthmembers are shown in the figures as having a round cross section. Alsothe optical fiber system is shown with a round cross section. Either ofthese shapes may be varied.

Optical fiber cable intended for drop applications typically has, incable terms, relatively small dimensions and relatively few, for example1-12, optical fibers. The overall width may be less than 0.5 in. Thethickness will typically vary from 0.3 to 0.7 times the width. Thepreferred cross section is a “racetrack” shape, a descriptive term usedhere to define two half circles joined by approximately straight lines.Preferably, but not essential, the two half circles have the sameradius. The symmetrical configuration, in either a racetrack or FIG. 8shape, has several practical advantages. It mimics the shape of variouscopper cables that are widely used. Among these are A-drop aerial coppercable, C-drop buried copper cable, and F-drop self-support copper cable.This provides a compatibility feature that appeals to customers. It alsoallows portions of previously installed equipment to be re-used, forexample, connector hardware.

The term strength member is defined as a strand of material with atensile strength substantially greater than the material surrounding thestrength member. Strength members are well known and widely used incable technology, so the meaning of the term should be clear anddefinite.

The optical fibers in the optical fiber subunit may be bundled or may beformed as an optical fiber ribbon. In the latter case, the optical fibersubunit may have the structure shown in FIG. 6, i.e. with encasement 14absent.

For some applications, for example in buried installations, it may bedesirable to include a water-blocking agent in the cable. A waterswellable yarn in the vicinity of the contact zone between the SMsubunit 13 and the OF subunit 12 would suit that purpose. A yarn mayalso be used as a rip cord to aid in separating the subunits duringinstallation.

Various other modifications of this invention will occur to thoseskilled in the art. All deviations from the specific teachings of thisspecification that basically rely on the principles and theirequivalents through which the art has been advanced are properlyconsidered within the scope of the invention as described and claimed.

1. Optical fiber cable comprising an optical fiber subunit and astrength member subunit, wherein both subunits are encased in a commoncable encasement, and both subunits contain at least one strengthmember.
 2. The optical fiber cable of claim 1 wherein the strengthmember subunit consists essentially of a strength member.
 3. The opticalfiber cable of claim 2 wherein the strength member comprises steel. 4.The optical fiber cable of claim 2 wherein the strength member comprisesa non-metallic, continuous-fiber reinforcement.
 5. The optical fibercable of claim 2 wherein the strength member subunit additionallycomprises a polymer encasement encasing the strength member.
 6. Theoptical fiber cable of claim 1 wherein the optical fiber subunitcomprises at least one optical fiber and a first encasement layerconformally coating the at least one optical fiber.
 7. The optical fibercable of claim 6 wherein the optical fiber subunit comprises a secondencasement conformally coating the first encasement, and the secondencasement contains at least one strength member.
 8. The optical fibercable of claim 7 wherein the second encasement contains two strengthmembers, with the at least one optical fiber located between the twostrength members.
 9. The optical fiber cable of claim 8 wherein the atleast one optical fiber and the two strength members are aligned along acommon axis.
 10. The optical fiber cable of claim 1 wherein the cablecross section has a racetrack shape.
 11. The optical fiber cable ofclaim 1 wherein the optical fiber subunit contains a single opticalfiber.
 12. The optical fiber cable of claim 1 wherein the optical fibersubunit comprises two or more optical fibers bundled together.
 13. Theoptical fiber cable of claim 1 wherein the optical fiber subunitcomprises two or more optical fibers ribboned together.
 14. The opticalfiber cable of claim 7 wherein the interface between the first andsecond encasements is a continuous polymer-to-polymer interface.
 15. Theoptical fiber cable of claim 14 wherein the first encasement is extrudedover the at least one optical fibers.